New at Fleur Plastics: In-Mold Labeling (IML) for hard cups

Fleur Plastics is continuously developing and always looking for ways to produce even more cost-effectively for our customers. For a project involving the production of hard cups, a completely new production line has been put into operation, which can efficiently and quickly produce custom cups using an eight-cavity mold and an In-Mold Labeling system.

The production process: eight-cavity mold and In-Mold Labeling

Hard cups are the replacements for the traditional plastic disposable cups that were often seen at large events. These new cups, which Fleur Plastics produces in both 20-centiliter and 25-centiliter sizes, have become a popular alternative to traditional cups since the ban on disposable plastic in the Netherlands. As a result, we are seeing a rapid increase in demand for these hard cups, and we have been looking for ways to meet this high demand.

The hard cups that Fleur Plastics produces are manufactured using an eight-cavity mold, for which a new ARBURG injection molding machine was specially purchased. The eight-cavity mold ensures that multiple products are molded and cooled simultaneously, making the production process eight times faster than using a single-cavity mold. This allows us to meet the high demand for the cups that are being used at more and more events.

In addition to producing the polypropylene hard cup, there was also the desire to personalize the cups directly. Many of the festivals and events where these cups are used wanted a personalized cup right away.

With this in mind, Fleur Plastics entered into discussions with an automation company. Recently, a six-axis robot has been installed in Fleur Plastics' production hall, which facilitates In-Mold Labeling. In this process, a PP label is printed with the customer’s desired design. These labels are laminated to make them dishwasher-safe and more scratch-resistant. The label is placed in the mold, where the back of the label fuses with the cup, ensuring they are firmly attached to each other.

The benefits of IML-produced hard cups

One of the benefits is that both the cup and the label are made from the same material (polypropylene, PP). This ensures that the label and cup do not need to be separated for recycling. Additionally, the process is more efficient than applying a separate print. This not only takes more time and energy but also generates more waste.

In this way, Fleur Plastics plays an important role in further enhancing the sustainability of festivals where less disposable plastic is already being used. Thanks to the material and the labeling, it is also possible to wash and reuse the cups after use.